US20100029159A1 - Heterocycle-containing aromatic polyamide fiber, method for producing the same, cloth constituted by the fiber, and fiber-reinforced composite material reinforced with the fiber - Google Patents

Heterocycle-containing aromatic polyamide fiber, method for producing the same, cloth constituted by the fiber, and fiber-reinforced composite material reinforced with the fiber Download PDF

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Publication number
US20100029159A1
US20100029159A1 US12/517,682 US51768207A US2010029159A1 US 20100029159 A1 US20100029159 A1 US 20100029159A1 US 51768207 A US51768207 A US 51768207A US 2010029159 A1 US2010029159 A1 US 2010029159A1
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Prior art keywords
heterocycle
aromatic polyamide
containing aromatic
fibers
polyamide fibers
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US12/517,682
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Inventor
Shigeru Ishihara
Yasuhiro Marumoto
Noriko Wada
Hajime Izawa
Hiromi Ozaki
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Teijin Ltd
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Individual
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Assigned to TEIJIN TECHNO PRODUCTS LIMITED reassignment TEIJIN TECHNO PRODUCTS LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ISHIHARA, SHIGERU, IZAWA, HAJIME, MARUMOTO, YASUHIRO, OZAKI, HIROMI, WADA, NORIKO
Publication of US20100029159A1 publication Critical patent/US20100029159A1/en
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G69/00—Macromolecular compounds obtained by reactions forming a carboxylic amide link in the main chain of the macromolecule
    • C08G69/02—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids
    • C08G69/26—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids derived from polyamines and polycarboxylic acids
    • C08G69/32—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids derived from polyamines and polycarboxylic acids from aromatic diamines and aromatic dicarboxylic acids with both amino and carboxylic groups aromatically bound
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/04—Particle-shaped
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G73/00—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups C08G12/00 - C08G71/00
    • C08G73/06—Polycondensates having nitrogen-containing heterocyclic rings in the main chain of the macromolecule
    • C08G73/18—Polybenzimidazoles
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/046—Reinforcing macromolecular compounds with loose or coherent fibrous material with synthetic macromolecular fibrous material
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D10/00—Physical treatment of artificial filaments or the like during manufacture, i.e. during a continuous production process before the filaments have been collected
    • D01D10/02—Heat treatment
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/60—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides
    • D01F6/605—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides from aromatic polyamides
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/78—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products
    • D01F6/80—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products from copolyamides
    • D01F6/805—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products from copolyamides from aromatic copolyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/919—Thermal treatment of the stream of extruded material, e.g. cooling using a bath, e.g. extruding into an open bath to coagulate or cool the material
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D10B2331/021—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides aromatic polyamides, e.g. aramides
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3976—Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]

Definitions

  • the present invention relates to heterocycle-containing aromatic polyamide fibers, a method for producing the same, a cloth constituted by the fibers, and a fiber-reinforced composite material reinforced with the fibers. More specifically, it relates to aromatic polyamide fibers that are excellent in balance among mechanical characteristics, particularly balance among a tensile strength, an initial modulus and a strength in the direction perpendicular to the fiber axis, and exhibit a high strength holding ratio under heat and humidity, as compared to conventional aromatic polyamide fibers, a method for producing the same, a cloth constituted by the fibers excellent in flame retardancy and bulletproofness, and a fiber-reinforced composite material reinforced with the fibers thereby being improved in reinforcing effect as much as possible.
  • Aromatic polyamide fibers containing an aromatic dicarboxylic acid component and an aromatic diamine component have been widely used for industrial purposes and clothing purposes by using the characteristics thereof including strength, high elastic modulus and high heat resistance.
  • para-series aromatic polyamide fibers (which may be hereinafter referred to as para-aramid fibers) are widely used for a protective clothing purpose, such as working wear, working glove and the like, a friction material, such as a brake pad for a vehicle and the like, a reinforcing material for tire or optical fibers, and the like, owing to their high rigidity, high heat resistance and excellent wear resistance.
  • para-series aromatic polyamide fibers include poly-p-phenyleneterephthalamide (PPTA) fibers, and the fibers have many advantages. However, there are points that are necessarily improved, for example, they involve problems in a spinning process since they are produced by a so-called liquid crystal spinning method utilizing optical anisotropy of a polymer dope, they are not necessarily high in strength among the mechanical characteristics of the fibers, they are insufficient in ductility due to low extension, they are insufficient in strength in the direction perpendicular to the fiber axis.
  • PPTA poly-p-phenyleneterephthalamide
  • aromatic polyamide fibers have been proposed that are improved in mechanical characteristics by introducing a heterocycle-containing monomer while maintaining the optical anisotropy (see, for example, JP-A-51-8363 and the like).
  • Such aromatic copolyamide fibers have been developed that have high solubility to a known amide solvent to facilitate spinning thereof, and have a high tensile strength and a high initial modulus.
  • JP-A-7-300534, JP-A-278303 and CN 14733969A propose an aromatic copolyamide that contains a heterocycle-containing monomer as a repeating unit and can form an isotropic solution with an amide solvent.
  • the aromatic copolyamide can be easily formed into fibers, thereby providing fibers that have a high tensile strength and a high initial modulus as compared to the conventional products.
  • para-series aromatic polyamide fibers are excellent in flame retardancy as compared to the conventional clothing fibers, such as nylon, polyester and the like, as understood from the LOI (limiting oxygen index) thereof of 29.
  • LOI limiting oxygen index
  • para-series aromatic polyamide fibers that are further enhanced in flame retardancy owing to increasing demand for capability thereof in various fields including fire retardant curtain for hospital or the like, a seat cover for aircraft, and the like.
  • JP-B-55-51069 proposes a method, in which meta-aramid fibers, which are represented by poly-m-phenyleneisophthalamide fibers, are heat-treated with an aromatic amine and then treated with a halogen-substituted phosphazene or the like to impart flame retardancy.
  • the flame retarder is not necessarily fixed sufficiently to a para-aramid, which has higher crystallinity than a meta-aramid, and thus flame retardant para-aramid fibers having durability cannot be obtained.
  • Patent Document 2 A method of mixed spinning meta-aramid fibers and para-aramid fibers as disclosed in JP-A-1-221537 (Patent Document 2), a method of using a woven fabric of flame retardant wool fibers and para-aramid fibers in a two-layer structure as disclosed in JP-A-3-837, and the like have been attempted, but a product that have sufficient capability has not yet been obtained.
  • JP-A-7-197317 a method of enhancing flame retardancy by adding a flame retarder upon spinning para-aramid fibers is attempted, but the method is restricted in selection of the flame retarder, and moreover, fibers having sufficient strength cannot be obtained.
  • Such flame retardant cloth and clothing have been proposed that uses polybenzazole fibers having higher flame retardancy than aramid fibers for enhancing the flame retardancy. Although the flame retardancy is enhanced by using the fibers, the fibers are considerably expensive, and therefore the cloth and clothing using the fibers are also expensive.
  • An object of the invention is to provide aromatic polyamide fibers that are excellent in balance among mechanical characteristics, particularly balance among a tensile strength, an initial modulus and a strength in the direction perpendicular to the fiber axis, and exhibit a high strength holding ratio under heat and humidity, as compared to conventional aromatic polyamide fibers, and a method for producing aromatic polyamide fibers that is capable of producing the same stably.
  • an oriented thread which is spun from a dope of a heterocycle-containing aromatic polyamide and is stretched after spinning, is heat-treated in a non-oxygen atmosphere or a low oxygen atmosphere, thereby providing aromatic polyamide fibers that are excellent in balance among a tensile strength, an initial modulus and a strength in the direction perpendicular to the fiber axis, and exhibit a high strength holding ratio under heat and humidity, and thus the invention has been completed.
  • the invention provides:
  • Heterocycle-containing aromatic polyamide fibers containing a heterocycle-containing aromatic polyamide characterized in that the fibers have a tensile strength of 20 cN/dtex or more, an initial modulus of 500 cN/dtex or more and a sulfuric acid soluble amount of 45% or less according to the following measuring method.
  • the heterocycle-containing aromatic polyamide fibers are added to concentrated sulfuric acid having a concentration of 97% to make a concentration of the heterocycle-containing aromatic polyamide fibers of 10 mg/10 mL and dissolved therein at 20° C. for 24 hours to provide a solution, which is measured for molecular weight distribution and a peak area (P1) by size exclusion chromatography (produced by Spark Holland B.V.).
  • the heterocycle-containing aromatic polyamide before forming fibers is similarly measured for molecular weight distribution and a peak area (P0) under the same conditions.
  • a value calculated from the resulting P1 and P0 according to the following expression is designated as a sulfuric acid soluble amount.
  • a fiber-reinforced composite material containing heterocycle-containing aromatic polyamide fibers and a matrix resin characterized in that a content of the matrix resin is from 30 to 70% by mass based on the total amount of the composite material, and the heterocycle-containing aromatic polyamide fibers are the heterocycle-containing aromatic polyamide fibers as described in the item (1).
  • the heterocycle-containing aromatic polyamide fibers of the invention are fibers that are produced from a heterocycle-containing aromatic polyamide-containing dope and have the following specific properties.
  • the properties, the constitution, the production method and the like of the heterocycle-containing aromatic polyamide fibers of the invention will be described below.
  • the tensile strength of the heterocycle-containing aromatic polyamide fibers of the invention is 20 cN/dtex or more, preferably 25 cN/dtex or more, and more preferably 30 cN/dtex or more. In the case where the tensile strength is less than 20 cN/dtex, sufficient reinforcing effect may not be exhibited upon using as reinforcing fiber for a composite material.
  • the “tensile strength” in the invention is a value obtained by performing a tensile test according to the method disclosed in JIS L1013.
  • the initial modulus of the heterocycle-containing aromatic polyamide fibers of the invention is 500 cN/dtex or more, preferably 600 cN/dtex or more, and more preferably 850 cN/dtex or more. In the case where the initial modulus is less than 500 cN/dtex, sufficient reinforcing effect may not be exhibited upon using as reinforcing fiber for a composite material.
  • the “initial modulus” in the invention is a value obtained by performing a tensile test according to the method disclosed in JIS L1013.
  • the sulfuric acid soluble amount of the heterocycle-containing aromatic polyamide fibers of the invention by the following measuring method is 45% or less. In the case where the sulfuric acid soluble amount exceeds 45%, the crosslinked structure, which is considered to be ascribable to hydrogen bond and covalent bond, is not sufficiently formed, and thus the tensile strength and the initial modulus are not improved.
  • the crosslinked structure is excessively formed since the mutual action among molecular chains is too strong, and fuzz and monofilament breakage are liable to occur in a yarn-making step.
  • the heterocycle-containing aromatic polyamide fibers are added to concentrated sulfuric acid having a concentration of 97% to make a concentration of the heterocycle-containing aromatic polyamide fibers of 10 mg/10 mL and dissolved therein at 20° C. for 24 hours to provide a solution, which is measured for molecular weight distribution and a peak area (P1) by size exclusion chromatography (produced by Spark Holland B.V.).
  • the heterocycle-containing aromatic polyamide before forming fibers is similarly measured for molecular weight distribution and a peak area (P0) under the same conditions.
  • a value calculated from the resulting P1 and P0 according to the following expression is designated as a sulfuric acid soluble amount.
  • a fraction that is insoluble in sulfuric acid is an insoluble fraction owing to crosslinking of molecular chains, which is considered to be ascribable to hydrogen bond and covalent bond. Accordingly, a small sulfuric acid soluble amount means a large fraction of molecular chains that are crosslinked and thus means a large strength in the direction perpendicular to the fiber axis. However, even when the sulfuric acid soluble amount is too smaller, the strength in the direction perpendicular to the fiber axis is not increased as proportional to the value as long as the sulfuric acid soluble amount is 45% or less, and therefore, the tensile strength and the initial modulus may not be necessarily improved.
  • the tensile strength holding ratio of the heterocycle-containing aromatic polyamide fibers of the invention after exposing to an atmosphere of a temperature of 37° C. and a relative humidity of 95% for 1,400 hours is 90% or more, preferably 95% or more, and more preferably 99% or more.
  • the tensile strength holding ratio is not preferably less than 90% since in the case, for example, where a bulletproof cloth is formed therefrom and used under a high heat and humidity environment, the strength of the cloth is decreased.
  • the “tensile strength holding ratio” in the invention is a value obtained by the following measuring method.
  • the heterocycle-containing aromatic polyamide fibers of the invention after exposing to an atmosphere of a temperature of 37° C. and a relative humidity of 95% for 1,400 hours are measured for tensile strength (St1) according to the method disclosed in JIS L1013, and a value calculated from St1 and the tensile strength (St0) before the heat treatment according to the following expression is designated as a strength holding ratio.
  • the heterocycle-containing aromatic polyamide referred in the invention is a polymer having one kind or two or more kinds of divalent aromatic groups that are directly bonded through an amide bond and containing a heterocycle.
  • the position of the heterocycle contained is not particularly limited and may be any of the main chain or the side chain, and the heterocycle may form an aromatic group along with the aromatic ring.
  • the aromatic group includes one containing two aromatic rings that are bonded through oxygen, sulfur or an alkylene group, and one containing two aromatic rings that are bonded directly.
  • the divalent aromatic group may contain a lower alkyl group, such as a methyl group, an ethyl group and the like, a methoxy group, a halogen group, such as a chlorine group and the like, and the like.
  • the position of the amide bond that directly bonds the divalent aromatic groups is not limited, and may be any one of a para-type and a meta-type.
  • the heterocycle-containing aromatic polyamide used in the invention can be obtained by using an aromatic dicarboxylic acid chloride and an aromatic diamine as raw materials and reacting them.
  • a heterocycle-containing compound is used as a part of the aromatic diamine to introduce a heterocycle.
  • the aromatic dicarboxylic acid chloride used as a raw material for the heterocycle-containing aromatic polyamide used in the invention is not particularly limited, and ordinarily known ones may be used.
  • Examples of the aromatic dicarboxylic acid chloride include terephthalic acid dichloride, 2-chloroterephthalic acid dichloride, 3-methylterephthalic acid dichloride, 4,4′-biphenyldicarboxylic acid dichloride, 2,6-naphthalenedicarboxylic acid dichloride, isophthalic acid dichloride and the like.
  • the aromatic diamine used as a raw material for the heterocycle-containing aromatic polyamide used in the invention is preferably, as apart or entire component thereof, a heterocycle-containing compound.
  • a heterocycle-containing compound for example, it is preferred that two kinds of aromatic diamines are used, and one of them is a heterocycle-containing aromatic diamine.
  • the aromatic diamine that does not contain a heterocycle is preferably one selected from a para-type aromatic diamine since it is excellent in mechanical characteristics of fibers obtained, and the aromatic ring thereof may be substituted or may not be substituted.
  • aromatic diamine that does not contain a heterocycle ordinarily known ones, such as p-phenylenediamine, p-biphenylenediamine and the like, may be used.
  • the aromatic diamine containing a heterocycle is not particularly limited, one selected from an aromatic diamine compound having a substituted or unsubstituted phenylbenzimidazole skeleton is preferred since the crosslinked structure, which is considered to be ascribable to hydrogen bond, is formed sufficiently.
  • 5(6)-amino-2-(4-aminophenyl)benzimidazole is preferably used since it is excellent in availability, tensile strength of fibers obtained, initial modulus and the like.
  • the heterocycle-containing aromatic polyamide used in the invention preferably contains the structural repeating unit represented by the following formula (1) in an amount of from 30 to 100% by mol based on the total amount of the repeating units.
  • the reaction solution is turbid in polymerization reaction, and a turbid dope is necessarily spun in the subsequent spinning step, thereby making spinning difficult.
  • the content of the structural repeating unit represented by the formula (1) is preferably from 50 to 100% by mol.
  • Ar 1 represents a divalent aromatic residual group, and hydrogen of the aromatic ring thereof may be partly or entirely substituted by a lower alkyl group, a methoxy group or a halogen group.
  • examples of the other structural repeating unit than the structural repeating unit represented by the formula (1) include a structural repeating unit represented by the following formula (2).
  • the content of the structural repeating unit represented by the formula (2) may be the entire of the balance of the structural repeating unit represented by the formula (1) or may be a part of the balance.
  • Ar2 and Ar3 may be the same as or different from each other and each represent an unsubstituted or substituent-containing divalent aromatic residual group.
  • the heterocycle-containing aromatic polyamide used in the invention can be produced according to a method that has been known in the art. Specifically, examples of the method include a method of reacting an aromatic dicarboxylic acid chloride and an aromatic diamine in an amide polar solvent.
  • Examples of the amide polar solvent used in production of the heterocycle-containing aromatic polyamide include N,N-dimethylformamide, N,N-dimethylacetamide, N-methyl-2-pyrrolidone, dimethylimidazolidinone and the like.
  • N-methyl-2-pyrrolidone is preferably used since it is excellent in handleability and stability in a series of steps of from polymerization of the heterocycle-containing aromatic polyamide to preparation of a dope and wet spinning step, and is less toxic as a solvent.
  • a known inorganic salt is preferably added in a suitable amount for the purpose of enhancing the solubility of the heterocycle-containing aromatic polyamide in the amide polar solvent.
  • the time for adding the inorganic salt is not particularly limited, and it may be added at arbitrary time, such as before starting polymerization, during or after polymerization, and the like.
  • Examples of the inorganic salt that may be added include lithium chloride, calcium chloride and the like.
  • the addition amount thereof is preferably in a range of from 3 to 10% by mass based on the amide polar solvent.
  • the addition amount exceeding 10% bymass is not preferred since it is difficult to dissolve the total amount of the inorganic salt in the amide polar solvent.
  • the addition amount less than 3% by mass is not preferred since the solubility of the heterocycle-containing aromatic polyamide not sufficiently enhanced.
  • a basic inorganic compound such as sodium hydroxide, potassium hydroxide, calcium hydroxide, calcium oxide and the like, is preferably added to perform neutralization reaction.
  • the concentration of the polymer produced by the polymerization reaction in the amide polar solvent is important for providing a homogeneous polymer having a high polymerization degree.
  • the concentration of the polymer produced is preferably 10% by mass or less, and in particular, in the case where the concentration is in a range of from 3 to 8% by mass, a homogeneous polymer having a high polymerization degree can be provided stably.
  • the heterocycle-containing aromatic polyamide fibers of the invention are produced by using a dope containing the heterocycle-containing aromatic polyamide obtained in the aforementioned production method through a spinning step, a stretching step and a heat-treating step described below.
  • the heterocycle-containing aromatic polyamide-containing dope is ejected from a discharging hole provided in a die into a coagulation bath to provide an unstretched thread.
  • the heterocycle-containing aromatic polyamide-containing dope used in the invention may be a solution that contains the heterocycle-containing aromatic polyamide produced in the aforementioned production method of a heterocycle-containing aromatic polyamide dissolved in the solvent for producing in the method, or the heterocycle-containing aromatic polyamide in the form of particles or the like separated may be dissolved in a solvent to provide a solution, which may be used as the dope.
  • a solution containing the heterocycle-containing aromatic polyamide dissolved in the solvent that has been used as the production solvent is preferably used as it is as the dope since the separating step of the heterocycle-containing aromatic polyamide can be omitted.
  • other arbitrary component such as an additive and the like, may be introduced upon preparing the dope in such a range that does not deviate from the substance of the invention.
  • the introducing method is not particularly limited, and for example, the arbitrary component may be introduced to the dope by using a extruder, a mixer or the like.
  • the heterocycle-containing aromatic polyamide-containing dope is discharged in a coagulation solution according to the known production method for aromatic polyamide fibers to provide an unstretched thread.
  • the coagulation solution used herein is an aqueous solution constituted by two components including an amide solvent and water.
  • the amide solvent used is preferably N-methyl-2-pyrrolidone since it is excellent in handleability and stability and is less toxic as a solvent.
  • the concentration of the amide solvent in the coagulation solution is preferably from 10 to 50% by mass. In the case where the concentration of the amide solvent exceeds 50% by mass, coagulation of the heterocycle-containing aromatic polyamide dope does not proceed to cause adhesion between the unstretched threads obtained, thereby making continuous spinning difficult.
  • the concentration is not preferably less than 10% by mass since plasticization of the unstretched thread does not proceed sufficiently, thereby decreasing the stretching property in the stretching step performed subsequently.
  • the temperature of the coagulation bath is preferably selected appropriately depending on the coagulation bath since the temperature closely relates to the composition of the coagulation bath, and the temperature is not preferably too high since the resulting unstretched threads are significantly adhered to each other, and the workability is deteriorated.
  • the temperature of the coagulation bath is suitably in a range of from 0 to 50° C.
  • the unstretched thread obtained in the spinning step is stretched to provide an oriented thread.
  • the unstretched thread of the heterocycle-containing aromatic polyamide formed in the coagulation bath in the spinning step is taken out from the coagulation bath. Thereafter, the unstretched thread thus taken out is transported to an aqueous solution for stretching containing two components including an amide solvent and water, and is stretched in the aqueous solution to a ratio of from 1.2 to 5.0 times to provide an oriented thread.
  • the amide solvent used is preferably N-methyl-2-pyrrolidone since it is excellent in handleability and stability and is less toxic as a solvent.
  • the concentration of the amide solvent in the aqueous solution for stretching is preferably in a range of from 30 to 80% by mass.
  • concentration of the amide solvent exceeds 80% by mass, the heterocycle-containing aromatic polyamide thread is dissolved in the aqueous solution for stretching, thereby making continuous formation of the oriented thread difficult.
  • concentration of the amide solvent is less than 30% by mass, plasticization of the resulting oriented thread does not proceed sufficiently, and thus it is difficult to ensure the aforementioned stretching ratio.
  • the temperature of the aqueous solution for stretching is not particularly limited, and in the case where the temperature is too high, the heterocycle-containing aromatic polyamide threads are significantly adhered to each other, and the workability is deteriorated.
  • the temperature of the aqueous solution for stretching is preferably in a range of from 0 to 50° C.
  • a water washing step and a drying step are performed as preliminary procedures toward a heat-treating step.
  • the aqueous solution for stretching is sufficiently removed from the resulting heterocycle-containing aromatic polyamide oriented thread by washing with water.
  • the oriented thread, from which the aqueous solution for stretching has been removed is sufficiently dried in the drying step for preparing for the subsequent heat-treating step.
  • the oriented thread thus obtained is heat-treated in a non-oxygen atmosphere or a low oxygen atmosphere having an oxygen concentration of 1% by volume or less to provide heterocycle-containing aromatic polyamide fibers.
  • the oxygen concentration upon heat treatment a non-oxygen atmosphere or a low oxygen atmosphere having an oxygen concentration of 1% by volume or less is employed.
  • the oxygen concentration is preferably 0.5% by volume or less, and more preferably 0.2% by volume or less.
  • the oxygen concentration exceeds 1% by volume upon heat treatment, decomposition of the polymer chain is accelerated, whereby it is difficult to attain balance between high strength of the fibers and strength in the direction perpendicular to the fiber axis.
  • the heat-treating temperature in the heat-treating step is preferably in a range of from 300 to 550° C.
  • the heat-treating temperature is less than 300° C.
  • sufficient orientation crystallization cannot be achieved, whereby it is difficult to provide fibers having sufficient tensile strength and initial modulus.
  • crosslinking cannot be sufficiently formed, whereby it is difficult to provide strength in the direction perpendicular to the fiber axis.
  • the heat-treating temperature exceeds 550° C., on the other hand, the fibers suffer heat deterioration, whereby it is difficult to provide sufficient tensile strength and initial modulus.
  • the heat-treating time in the heat-treating step is preferably 1 minute or less. In the case where the heat-treating time exceeds 1 minute, decomposition of the polymer chain is accelerated, whereby it is difficult to provide fibers having high strength.
  • the tension of the fibers upon heat-treating is preferably more than 1.0 cN/tex and 3.0 cN/tex or less.
  • the tension is 1.0 cN/tex or less, sufficient molecular chain orientation cannot be obtained, whereby it is difficult to attain high strength.
  • the tension exceeds 3.0 cN/tex, on the other hand, fuzz frequently occurs on the fibers, which may provides cases where fibers with good quality are difficult to provide.
  • the fineness of the heterocycle-containing aromatic polyamide oriented thread subjected to the heat-treating step is preferably in a range of from 0.55 to 22 dtex, and particularly preferably in a range of from 1.67 to 16.7 dtex, in terms of monofilament fineness.
  • the monofilament fineness is not preferably less than 0.55 dtex since fuzz and monofilament breakage are liable to occur in a yarn-making step of the fibers obtained. It preferably does not exceed 22 dtex since thread twisting or net manufacture is difficult to perform.
  • the thread of the flame retardant heterocycle-containing aromatic polyamide fibers thus produced in the aforementioned manner is subjected to thread twisting, crimping and the like depending on necessity, and then formed into a cloth, such as a knitted fabric, a woven fabric, a nonwoven fabric and the like, according to a known method.
  • the cloth exhibits a considerably high LOI (limiting oxygen index) of 32 or more, and preferably from 32 to 42, in a flame retardation test according to the method of JIS K7201.
  • the flame retardant aromatic copolyamide fiber cloth is laminated into plural layers in many cases and used as a laminate, and in the laminate, the aromatic copolyamide fiber cloth may be used solely or may be used in combination with another high strength fiber cloth.
  • the high strength fiber cloth to be used in combination is a cloth of fibers having a tensile strength of 20 cN/dtex or more, such as other aramid fibers, polyarylate fibers, polybenzazole fibers and the like.
  • the flame retardant cloth of the invention not only is useful as a material for a flame retardant clothing, such as aerospace clothing, military clothing, turnout closing for security personnel, fire fighting clothing for fire brigade personnel, work clothing used in front of a blast furnace, and the like, but also can be effectively used in the fields including fire retardant and flame retardant curtain, a seat for aircrafts and automobiles, and the like. In these cases, a small amount of electroconductive fibers may be mixed and woven in the cloth to prevent static charge from occurring.
  • the thread of the heterocycle-containing aromatic polyamide fibers produced in the aforementioned method is subjected to thread twisting, crimping and the like depending on necessity, and then formed into a bulletproof cloth, such as a knitted fabric, a woven fabric, a nonwoven fabric and the like, according to a known method.
  • a bulletproof cloth such as a knitted fabric, a woven fabric, a nonwoven fabric and the like.
  • the fibers are aligned in one direction each for warp and weft threads to facilitate exhibition of the capabilities of the fibers, and thus high bulletproof capability is liable to be attained.
  • the form of the woven structure can be easily maintained to prevent the texture from opening. Accordingly, it is preferred since the fibers are not deviated upon bullet landing, and the capabilities of the fibers are not lost to exhibit high bulletproof capability.
  • the highly bulletproof heterocycle-containing aromatic polyamide fiber cloth is used as a laminate after laminating, and the laminate may be used solely or may be used in combination with another high strength fiber cloth.
  • the high strength fiber cloth used in combination is preferably a cloth of fibers having a tensile strength of 18 cN/dtex or more, such as other aramid fibers, polyarylate fibers, high strength polyethylene fibers and the like.
  • the thread of the heterocycle-containing aromatic polyamide fibers produced in the aforementioned method is subjected to thread twisting, crimping and the like depending on necessity, and then formed into a cutting resistant cloth, such as a knitted fabric, a woven fabric, a nonwoven fabric and the like, according to a known method.
  • a composite cloth having other fibers combined is also encompassed in the scope of the invention.
  • the other fibers herein include natural fibers, organic fibers, inorganic fibers, metallic fibers, mineral fibers and the like.
  • the combining method is not particularly limited, and an arbitrary method may be used, such as mixed weaving, combined knitting and weaving and the like.
  • the woven fabric may be a plane woven fabric, a double woven fabric, a ripstop fabric and the like, and the knitted fabric may be a circular knitted fabric, a weft knitted fabric, a warp knitted fabric, a raschel knitted fabric and the like.
  • the nonwoven fabric may be any one of a nonwoven fabric containing short fibers and a nonwoven fabric containing long fibers.
  • the short fiber nonwoven fabric may be a dry-laid nonwoven fabric or a wet-laid nonwoven fabric (including paper), and the long fiber nonwoven fabric may be a so-called spunbond nonwoven fabric or a tow filamentized nonwoven fabric, and may be a fabric containing long fibers aligned in one direction to form a sheet, which is laminated with other plural aligned fiber sheets to cross the aligned directions each other. If necessary, fibers of these nonwoven fabrics may be bonded to each other by using an adhesive or a thermal-bonding fiber in combination.
  • the nonwoven fabric may be subjected to a confounding treatment by a needle punch or a water jet.
  • the fiber bundle constituting the cloth is not particularly limited. Specifically, a monofilament, a multifilament, a twisted yarn, a mixed twisted yarn, a covering yarn, a spun yarn, a stretch breaking spun yarn, a core-shell structure yarn and the like may be used.
  • the cutting resistant cloth of the invention may be used partly or entirely in protective clothing or armors.
  • the matrix resin which is an essential component used for the case where the thread of the heterocycle-containing aromatic polyamide fibers produced in the aforementioned method is used as reinforcing fibers for a fiber-reinforced composite material, is not particularly limited as far as it can be composited with the heterocycle-containing aromatic polyamide fibers, and any one of a thermoplastic resin and a thermosetting resin may be used.
  • the thermoplastic resin include a polyethylene resin, a polypropylene resin, a polyamide resin, a polyester resin, a polycarbonate resin, a polyphenylenesulfide resin, a polyether ether ketone resin and the like.
  • the thermosetting resin include a phenol resin, a diallyl phthalate resin, an unsaturated polyester resin, an epoxy resin, a polyimide resin, a vinyl ester resin and the like.
  • the content of the matrix resin is in a range of from 30 to 70% by mass based on the total composite material. In the case where the content of the matrix resin is less than 30% by mass, it is difficult to produce a fiber-reinforced composite material containing the heterocycle-containing aromatic polyamide fibers that are dispersed homogeneously in the matrix resin. In the case where the content of the matrix resin exceeds 70% by mass, the fiber reinforcement effect of the resulting fiber-reinforced composite material is considerably lowered.
  • other arbitrary components may be introduced for the purpose of imparting functionality or the like in such a range that does not deviate from the substance of the invention.
  • known methods may be used, and examples thereof include a method, in which the arbitrary component is dispersed in the matrix resin in advance, and the matrix resin is then composited with the heterocycle-containing aromatic polyamide fibers.
  • the production method of the fiber-reinforced composite material of the invention is not particularly limited, and may be selected from known methods depending on the target shape and the kind of the matrix resin.
  • an optimum production method may be selected, for example, from a hand lay-up method, a cold press method, a resin injection method, a BMC method, an SMC method and the like.
  • the measurement was performed at 30° C. with 98% concentrated sulfuric acid as a solvent to measure the inherent viscosity.
  • the tensile strength and the initial modulus were calculated by performing a tensile test according to the method disclosed in JIS L1013.
  • the heterocycle-containing aromatic polyamide fibers after exposing to an atmosphere of a temperature of 37° C. and a relative humidity of 95% for 1,400 hours were measured for tensile strength (St1) according to the method disclosed in JIS L1013, and the tensile strength holding ratio was calculated from St1 and the tensile strength (St0) before the heat treatment according to the following expression.
  • the heterocycle-containing aromatic polyamide fibers were added to concentrated sulfuric acid having a concentration of 97% to make a concentration of the heterocycle-containing aromatic polyamide fibers of 10 mg/10 mL and dissolved therein at 20° C. for 24 hours to provide a solution, which was measured for molecular weight distribution and a peak area (P1) by size exclusion chromatography (produced by Spark Holland B.V.).
  • the heterocycle-containing aromatic polyamide before forming fibers was similarly measured for molecular weight distribution and a peak area (P0) under the same conditions.
  • a value calculated from the resulting P1 and P0 according to the following expression was designated as a sulfuric acid soluble amount.
  • the LOI limiting oxygen index
  • V50 value according to MIL-C-44050 (U.S. Military Specification) was used as an index of bulletproofness.
  • a 10 cm square frame (width: 1 cm, outer size: 11 ⁇ 11 cm, inner size: 10 ⁇ 10 cm) was fixed at an angle of 45°, to which a cloth to be tested was fixed.
  • NMP N-methyl-2-pyrrolidone
  • TDC terephthalic acid chloride
  • the heterocycle-containing aromatic polyamide deposited from the polyamide solution obtained after the neutralizing reaction was measured for inherent viscosity ( ⁇ inh), which was 5.5.
  • the heterocycle-containing aromatic polyamide solution obtained after the neutralizing reaction was used as a dope and discharged from a spinning die having a hole diameter of 0.15 mm and a number of holes of 25 at a rate of 2.5 cc per minute, thereby spinning through a gap part referred to as an air gap into an NMP aqueous solution (coagulation solution) having an NMP concentration of 30% at 50° C. to provide an unstretched thread (coagulated thread).
  • NMP aqueous solution coagulation solution having an NMP concentration of 30% at 50° C.
  • the resulting unstretched thread was plastically stretched at a stretching ratio of 2.0 in an NMP aqueous solution (aqueous solution for stretching) having an NMP concentration of 70% at 30° C.
  • the thread after stretching was washed with water, dried, and then subjected to a heat treatment under conditions of a temperature of 450° C. and an oxygen concentration of 0.2% by volume for 30 seconds. After the heat treatment, the thread was wound up at a rate of 30.0 m/min to provide heterocycle-containing aromatic polyamide fibers of 42 dtex per 25 fil.
  • Heterocycle-containing aromatic copolyamide fibers were produced in the same manner as in Example 1 except that heterocycle-containing aromatic polyamide were produced in the same manner as in Example 1, and the heat-treating conditions were those shown in Table 1.
  • the resulting heterocycle-containing aromatic polyamide fibers were subjected to various measurements in the same manner as in Example 1. The results are shown in Table 1.
  • Example 1 Example 2
  • Example 3 DAPBI (% by mol) 70 70 70 PPD (% by mol) 30 30 30 30 TDC (% by mol) 100 100 100 Oxygen concentration upon heat 0.2 0.2 5 treatment (% by volume) Heat treatment temperature (° C.) 450 420 420 Heat treatment time (min) 0.5 1.0 0.5 Sulfuric acid soluble amount (%) 40 3 10
  • Fineness (dtex) 42 42
  • Example 3 Example 4 DAPBI (% by mol) 70 70 70 70 PPD (% by mol) 30 30 30 30 30 TDC (% by mol) 100 100 100 100 100 Oxygen concentration upon heat 21 8 21 10 treatment (% by volume) Heat treatment temperature (° C
  • Heterocycle-containing aromatic polyamide fibers obtained in the same manner as in Example 1 were combined to provide a filament yarn of 1,176 dtex.
  • the filament yarn was twisted at a twisting coefficient of 6, and woven at a weave density of 45 per inch for each of warp and weft to provide a plane woven fabric having an areal weight of 210 g/m 2 .
  • the woven fabric had an LOI (limiting oxygen index) of 32 measured according to the method of JIS K7201.
  • Example 4 24 sheets of the plane woven fabric produced in Example 4 were laminated to provide a bulletproof woven fabric.
  • a bulletproofness test of the bulletproof woven fabric revealed V50 of 580 m/s.
  • Poly-p-phenyleneterephthalamide (PPTA) fibers of 1,100 dtex (Kevlar, a trade name, produced by DuPont) were twisted at a twisting coefficient of 7.6, and woven at a weave density of 30 per inch for each of warp and weft to provide a plane woven fabric having an areal weight of 285 g/m 2 . 18 sheets of the woven fabric were laminated, and the same bulletproofness test thereof revealed V50 of 494 m/s.
  • a spun yarn (thread size: 20/2) was produced by an ordinary method with heterocycle-containing aromatic polyamide fibers obtained in the same manner as in Example 1, and the spun yarn were used as warp and weft to weave a 2/1 twill fabric (areal weight: 280 g/m 2 ).
  • Example 6 The same procedures as in Example 6 were performed except that the fibers constituting the spun yarn in Example 6 were poly-p-phenyleneterephthalamide (PPTA) fibers (Kevlar, a trade name, produced by DuPont).
  • PPTA poly-p-phenyleneterephthalamide
  • the resulting twill fabric had cutting resistance of 0.7 kg.

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